Method of manufacturing covered-joint hinges



Jan. 15, 1929.

W. C. KENYON METHOD OF MANUFACTURING COVERED JOINT HINGES 3 Sheets-Sheet 1 Filed July I. 1925 Jan. 15, 1929.

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W. C. KENYON Jan. 15, 1929. 1,699,242

METHOD or unumcrunmccovnnanaomr amass" Filed July 1. 1925 3 sum-snug 3 Patented Jan. 15, 1929.

UNITED STATES.

PATENT OFFICE.

WILLIAM c. xnmromor nooxronn, ILLINOIS, ASSIGNOR TO THE ATWOOD new:

magma COMPANY, A cornnrnnnsnrr coNsIsTmG or SETH B. a'rwoon AND. JAMES '1. .a'rwoon, or nooxronn, ILLINOIS.

METHOD OF MANUFACTURING. COVERED-JOINT HINGES.

Application filed July 1, 1925. Serial No. 40,759.

This invention relates to covered joint hinges, so called because the knuckle joints are covered by the hinge structure when in use, and its primary object is to improve the method of manufacturing hinges of this class.

My invention further contemplates the manufacture of a covered. oint hinge of the character disclosed and claimed in my copending application, Serial No. 40,758, filed concurrently herewith, that is, one in which the outer hinge-member is in one piece and has a circular single roll knuckle which serves to cover the knuckle joints.

My invention also aims to reduce the cost of manufacturing hinges of this class and to promote strength, accuracy and uniformity in the resultant product.

By the practice of my invention I produce an outer hinge member, that is, the one that covers the knuckle joint, made of asingle piece of metal as distinguished from others in which the corresponding hingemember is made of plural parts. Furthermore, this onepiece hinge member is formed, preferably but not necessarily, by milling and curling or bending operationsto produce asingle roll slotted knuckle in which the single roll knuckle portion covers the knuckle joints when in use, as distinguished from others having a plural roll" knuckle portion.

Further objects consist in certain new and improved operations for forming the knuckle joint covering, and others for forming, slotting, boring, crowning, breaching and finishing the knuckle proper.

Other objects and attendant advantages will be appreciatedbv those skilled in this art as the invention becomes better understood by reference to the following description when considered in connection with the accompanying drawings, in which Figures 1 to 5 inclusive are views showing successive operations in manufacturing the inner hinge member;

Fig. 6, is a face view of the completed inner hinge member;

Fig. 7. is a side view of the inner and outer hinge members assembled, also showingin dotted lines a final milling operation;

Fig. 8, is a face view of the outer hinge member blank after the first milling operalines 9-9 and 101O respectively,

Figs. 9 and 10, are sections takenon the of Fig. 8;; Figs. 11 to 15 inclusive, are views showing certain succeeding operations;

Fig. 16, is a face view of the outer hinge member following the slotting operations shown in Fig. 15' i i Fig. 17, shows the offsetting operation;

Fig. 18, is a perspective view of the broaching tool or die;

Fig. 19, shows the operative relation of the growning tool or die to the outer hinge mem- Fig. 20, is a side view and Fig: 21, a lon tudinal section showing the cooperativeref tion of the broaching and crowning dies in performing their respective functions; and

Fig. 22, isa side view of. the com leted outer hinge member showing in dotte lines the operation of boring the pivot pin hole in the knuckle.

The complete hinge shown in Fig. 7 comprises the inner and outer hinge members designated generally by23 and 24 res ectively, and a pivot pin 25 connecting the 111tBIfit.- ting knuckles. It will be observed from this view that the knuckle of the inner hinge mem+ ber is almost entirely encompassed and covered on its periphery by the knuckle portion of the outer hinge member, thus covering the knuckle joints when the hinge is in use. The desirability of a covered joint hinge is well known in this art. The covered. joint herein disclosed is, however, an advance in the art for reasons explained. in mycopending application above mentioned, and the method of manufacturing this hinge is. likewise an advance and constitutes the subj ect matter of the present application.

Reference will be had first to Figs. 1 to 6 inclusive illustrating the method of manufacturing the inner hinge member. It will be noted, however, atthe outset that, it is desirable especially from the point of economy and strength to make each hinge member from a single piece of metal. I prefer to useflat stock of the samethickness for each hinge member, the first operation consisting in cutting this stock oil' into suitable lengths which constitute the blanks from which the respective hinge members are formed.

The first operation after cutting off the blanks for the inner hinge member 23, referred to hereinafter by the same reference numeral, is to mill off the fiat side 26 at one end to provide a reduced end portion from which the knuckle will be formed. Said end portion will then be turned back upon itself by the action of a stamping tool or die 2? which presses said portion into a form die 28, thus partially forming the knuckle 29. The end 31 of said partially formed knuckle will then be milled off as shown in Fig. 3. The next following operation consists in bending, curling or rolling said knuckle portion by endwise pressure of a tool 32 against the end 33 of the blank while it is confined between upper and lower forming dies 34 and 35 respectively, to complete the knuckle. This provides a circular single roll knuckle, the milled end 31 making a flush joint with the milled face 36. The knuckle is then milled through transversely by suitable milling cutters 37 to the depth shown in Fig. 5, the cutters being so placed as to produce, in this instance, a pair of spaced knuckle parts 38 shown in Fig. 6. After b ring out the knuckle hole and drilling the flat strap part of the inner hinge member for the reception of fastening screws or bolts if such are used, this member is substantially completed.

Regarding the outer hinge member it will be noted that my invention contemplates so forming, shaping or fashioning the single blank as to provide a single roll knuckle which serves also to cover the knuckle joints when the hinge members are assembled and ,in use. To this end I groove or otherwise shape one face of the blank to provide clearance for the knuckle of the complemental hinge member and, preferably, leave an ungrooved portion at one end from which to form part of the knuckle. In the preferred embodiment disclosed herein the blank 24 will be grooved adjacent to one end by milling cutters, providing shallow parallel grooves 39 and leaving an ungrooved end portion 41. It is not, however, essential that the portion l1 shall be ungrooved but it is preferred in order to retain intact a uniform body for making the initial. bend or bends for partially forming the knuckle and also for the reason that this end portion will be subsequently milled or slotted entirely through, as will be described later. The grooves 39 provide clearance for the spaced knuckle parts of the inner hinge member, and this grooved portion after it is further formed as will be presently described provides the covering for the hinge joints. Said grooves are preferably formed by milling cutters shaped to provide tapered sides 4E2, the pur pose of which will appear hereinafter. Said grooves may be milled with cutters of sufficiently large diameter fed in a plane perpendicular to that of the fiat blank; but I prefer to employ cutters of smaller diameter as indicated by reference numeral l3, Fig. 10, which will enter the blank at ell and feed gradually deeper into the blank as the nulling progresses lengthwise thereof. At the point of maximum depth indicated at the cutters will be withdrawn. The clearance grooves are thus increasing in depth toward the knuckle end of the blank but do not ex tend through to the opposite face of the blank.

The next stop .is to partially form the knuckle, as for example, by bending the end portion l1 of the blank to provide a substantially semi-circular knuckle portion. This may be done as shown in Fig. 11 by a stamp ing tool 46 and a form die 4:7 similar to the tool 27 and die 28 above mentioned. In this instance, however, with stock approximately one-quarter of an inch in thickness as used in automobile door hinges it is usually necessary to subject the blank to more than one stamping operation with the tool &6 in order to complete the bend. Following this the blank is subjected to endwise pressure of a tool 48 with its knuckle end in a form die 46) for slightly curling said end as shown in Fig. 12.

The next step is to form a depression 51 in the inner wall of the knuckle bent adjacent to and preferably coplanar with the side of the blank. This is done by a st: inping tool 52 while the blank is positioned on the die 4-9, this tool having a right angle corner which forms the depression and an opposite rounded corner which conforms to the contiguous inner wall of the knuckle portion. The purpose of this depression 51 is to provide lateral lead for a boring tool when boring the pivot pin hole as will be described later.

Following this the end of the partial knuckle will be milled off for the same purpose as milling the end 31 on the inner hinge members as above described. The partially formed knuckle will then be slotted transversely for the reception of the spaced knuckle parts 38 of the inner hinge member. The milling or slotting cutters 55 will cut entirely through the partially formed knuckle 441, the cutters being in alignment or registration with and preferably of the same width as the base of the grooves 39, thus forming the spaced knuckle parts 56 shown in Fig. 16. It will be noted that the cutters 55 intersect the outer side of the blank at the point 57, thus leaving an imperforate blank body except at the transverse slot openings.

The following operation consists in bond ing or curling the partially formed and slotted knuckle to a complete circular form. or in other words, to complete the knuckle. It will be noted that this is a single roll knuckle as distinguished from. those having plural rolls or convolutions. This curling operation is performed by endwise pressure of a tool 58 against the end of the blank remote from the portion and a cover the latter of which conceals the knuckle joints.

The next step is to crown and broach the knuc! sle and, while I perform these operations as one, they might be performed separately. The crowning operation consists in giving a crowned effect to the outer face of the knuckle body for purpose of finish. This is accomplished by a stamping operation with the knuckle confined between a crowning die 62 and an opposite die 63 which, in the pre ferred practice of my invention, is also a broaching die. As shown in Fig. 19 the die 62 is dished as indicated at 65 and this shape is continued partially around the periphery of the knuckle to produce the crowned effect. The die 63 is shaped to provide broaching cutters 66- which enter between the spaced knuckle parts 56 and the edges 67 of which perform a broaching operation in that they remove any burrs, rough edges or. surplus stock from the adjacent faces of said spaced knuckle parts. Viewing Fig. 21 it will be observed that the broaching cutters 66 are shaped to completely fill the space formed by the two milling operations above described, so that the broaching cutter edges are carried to the full depth of the clearance grooves and the ends of said cutters are preferably brought into contact with the bottom of said grooves. The broaching tool is also shaped to provide arcuate faces 68 adapted to seat on the curved peripheral spaces of the spaced knuckle parts opposite from the arcuate face 65 of the crowning die. As a result of this die construction when the breaching die is brought down onto the knuckle with sufficient force both end portions of the knuckle will be slightly displaced upwardly by reason of the shape of the crowning die in securing said crowned effect. At the same time the above mentioned broaching operation will be performed and, furthermore, the spaced knuckle parts 56 will be forced into alignment by reason of the opposed faces 65 and 68. This operation also corrects any dimensional variances in the spacing and location of the knuckle parts 56 and insures that their flat inner faces will be in parallel relation and accurately spaced apart so as to provide a proper fit and bearing for the complemental knuckle parts of the inner hinge member.

After the outer hinge member has thus been formed and fashioned the pivot pin hole will be bored with a drill or boring tool somewhat larger in diameter than thehole formed by bending and curling the knuckle. This hole 69, Fig. 22, will be eccentric to the periphery of the knuckle by reason of the lateral lead to the boring tool induced by the depression 51 above mentioned. The purpose of this eccentricity is to locate the pivot pin 25 and consequently the knuckle offthe inner hinge member closer to the open side of the outer hinge member knuckle and away from the internal wall of the covering portion of the latterknuckle.

The inner and outer hinge members will be assembled in the relation shown in Fig. 7

and while so assembled a final milling cut will be taken by a form cutter 71 to cut away the surfaces 72 of the outer knuckle parts 56 so that such faces are flush with the intervening'faces of the knuckle parts 38. The edge 73 formed by said milling cuts is coincident with the edge 57 of the knuckle covering portion and either or both of these edges may, if desired, be utilized as stops for limiting the opening movement of the hinge members.

It is believed that the foregoing conveys a clear understanding of the objects prefaced above and while I have illustrated and de scribed a preferred method of practicing my invention it should be understood that many changes might be madein the numberand order or sequence of the operations and in variations thereof without departing from the spirit and scope of the invention as ex? pressed in the appended claims, in which- I claim: a

1. The method of mannfacturingthe outer hinge member of a covered joint hinge con sisting in longitudinally grooving one face of a metal blank adjacent to one end, bending said end to form a partial knuckle, slotting,

said partial knuckle transversely in alignment with and intersecting said grooving, and bending or curling said partial knuckle to provide a single roll, circular knuckle with the iinperforate interiorly grooved knuckle portion in position to conceal the knuckle Joints when m use.

2. The method of manufacturing the outer hinge member of a covered joint hinge conslsting in shallow grooving the blank on one face to provide clearance for the knuckle of the complemental hinge member, bending the blank to provide a partial knuckle. milling through said partial knuckle in alignment with said grooving, and curling said partial knuckle on the grooved side of the blank to complete the knuckle.

3. The method of manufacturingthe outer hinge member of a covered joint hinge consisting in shallow grooving the blank on one face to provide clearance for the knuckle of the complement-a1 hinge member, bending the blank to provide a partial knuckle, mill- Cit ing through said knuckle in alignment with said grooving, and curling said partial knuckle on the grooved side of the blank to provide a single roll, circular knuckle the grooved imperforate portion of which is adapted to cover the hinge joints when in use. 7 l. ".l. he method oi manufacturing the outer hinge member of a covered joint hinge consisting in milling knuckle clearance grooves in one face of a blank adjacent to one end thereof and. leaving an unmilled end portion, turning said end portion toward the grooved side to provide partial knuckle, slotting said partial knuckle in alignment with said grooves, and further bending or curling said slotted knuckle portion to complete the knuckle.

5. The method of manufacturing the outer hinge member of a covered joint hinge consisting in milling knuckle clearance grooves in one face of a blank adjacent to one end thereof and leaving an unmilled end portion, turning said end portion toward the grooved side to provide a partial knuckle, slotting said partial knuckle in alignment with said grooves, "further bending or curling said slotted knuckle portion to complete the knuckle, and or wning the outer face of the knuckle portion by pressure of a crowning die engaging therewith and an opposed broaching die having breaching cutters which enter the knuckle slots.

6; The method of manufacturing a single roll, single piece covered joint hinge member consisting in grooving one side of the blank to provide clearance for the knuckle of the complemental hinge member, partially forming a knuckle on one end of the blank, slotting said partially formed knuckle in alignment with and intersecting said grooving,

- and further forming said partial knuckle to provide a complete single roll circular knuckle having said grooved imperforate portion in position to cover the hinge joint when in use.

7. The method of manufacturing a covered joint hinge member including the operation of milling one side of a blank to provide clearance grooves for the knuckle of the complementa-l hinge member prior to forming the knuckle, said knuckle clearance grooves being located adjacent to one end of the blank and terminating short of said end to provide an imperl'orate end portion adapted to be sub sequently formed into the knuckle proper and being gradually increased in depth from the end remote from said knuckle portion to a point of greatestdepth adjacent to the opposite end of the groove.

8. The method of mamifacturing a covered joint hinge member including the operation of milling one side of a blank to provide clearance grooves for the knuckle of the complemental hinge member, said grooves having tapered side walls diverging toward the face of the blank, and bending said grooved end of the blank to form a knuckle.

9. The method of manufacturing a covered joint hinge member from a flat metal blank consisting in grooving one side only of the blank to provide clearance for the knuckle or the eomplemental hinge member and bending or curling said grooved portion to provide a knuckle the joint of which is concealed by said grooved portion.

10. The method of manufacturing a covered joint hinge member including the operations of milling one side of a blank to provide a clearance groove for the knuckle of the complement-a1 hinge member, said groove being located adjacent to one end of the blank and leaving an imperitorate end portion, and subsequently forming said end portion and the adjoining grooved portion into a knuckle.

11. The method of mamitacturing a covered joint hinge member including the operations of milling one side oi a blank to provide clearance grooves for the knuckle of the complemental hinge member, said grooves being located adjacent to one end of the blank and leaving an impertorate end portion, and subsequently forming said end portion and the adjoining grooved portion into a knuckle by operations including partially forming the knuckle, and slotting the partially formed knuckle in registration with said clearance grooves.

12. The method oi manufacturing a covered oint hinge from a. flat metal blank consisting in milling a groove in one side only and lengthwise of the blank to partially form spaced knuckle parts and clearance for the knuckle of the complemental hinge member and to further provide an imperforate portion adapted to cover in part the knuckle j oint, slotting through the blank in alignment with the grooving at one end to provide separated knuckle parts, and bending or curling said separated knuckle parts and said grooved portion to provide a knuckle of which the separated parts leave an open side for admission oi? the said complemental knuckle and the grooved portion covers and conceals the joint at the opposite side.

13. The method of manufacturing a covered joint hinge member including the operations of forming a blank to provide clearance in one face thereof for the knuckle of the complemontal hinge member, said operation consisting in grooving said face of the blank so as to leave an imperttorato end p01 tion, and subsequently forming said end portion into a knuckle,

14-. The method of manufacturing a covered joint hinge member including the operations of forming a blank to provide clearance in one face thereof for the knuckle of the complemental hinge member, said operations consisting in grooving said face of the blankso asto leave an imperforate end portion adapted to be subsequently formed into the knuckle, the knuckle being formed by operations comprising bendin said-end portion toward the grooved side ofthe blank to provide an approximately semi-circular knuckle portion, slotting said knuckle portion in registration with and intersecting said clearance groove, and subsequently bending or curling said knuckle portion toward said grooved side to complete the knuckle.

15. The method of manufacturing a covered joint hinge member including the operations of forming a blank to provide clearance in one face thereof for the knuckle of the COfilPlElllellltll hinge member, said opera tions consisting in grooving said face of the blank so as to leave an imperforate end portion adapted to be subsequently formed into the knuckle, the knuckle being formed by operations comprising bending said end portion toward the grooved side of the blank to provide an approximately semi-circular knuckle portion, slotting said knuckle portion in registration with and intersecting said clearance grooves, and subsequently bending or curling said knuckle portion toward saidgrooved side to complete the knuckle, the

last mentioned ope 'ation forming a single roll, circular knuckle, said slotting operation consisting in slotting entirely through said partial knuckle portion and leaving the adjoining grooved portion imperforate so as to serve as a covering for the hinged oints when in use. 7

lb. The method of manufacturing a hinge member including the operations of bending 0r curling one end of a blank to provide a partial knuckle, and forming a depression along the inside of said knuckle portion to provide lateral lead for a boring tool when subsequently boring the knuckle for the hinge pin.

17. The method of manufacturing a hinge member including the operations of bending or curling one end of a blank to provide a partial knuckle, and forming a depression along the inside of said knuckle portion to provide lateral lead for a boring tool when subsequently boring the knuckle for the hinge pin, said depression being located substantially coplanar with the adjacent face of the Hat body of the hinge blank.

18. The method of manufacturing a hinge member including the operations of bending or curling one end of a blank to provide apartial knuckle, and forming a depression along the inside of said knuckle portion to provide lateral lead for a boring tool when subsequently boring the knuckle for the hinge pin, said depression being formed by a stamping tool having a substantially right angled corner the opposite corner of which is roundsaid knuckle portion. j l

19 i The method of manufacturing a covered oint hinge member consisting in grooved to conform to the contiguous inner wall of ing one side of a blank forclearance ofthe Y knuckle of a complemental hinge member and leaving an ungrooved end portion, forming.

said end portion to provide a partial knuckle, forming an angular depression along the inner Wall of said partial knuckle at the turn adjacent to the grooved side of the blank, slotting said partial knuckle in registration With said grooving, bending or curling said partial knuckle toward said grooved side to complete the knuckle, and boring the knuckle hole to produce a pivot pin hole eccentric with respect to the periphery of the knuckle.

20. The method of manufacturing a covered joint hinge knuckle including the operations of grooving one sideof a blank to provide clearance for the knuckle of the complemental hinge member, forming a depression across the grooved side to give latera lead to a boring tool for boring the pivot pin hole after the knuckle has been formed, and fashioning the knuckle by bending or curlin one end of the blank toward the grooved si e.

21. The method of manufacturing a covered joint hinge member including the operations of grooving one side ofa blankto provide clearance for the knuckle of the complemental hinge member, forming the knuckle by bending or curling one end of the blank toward the grooved side, and forming the pivot pin hole eccentric with respect to the periphery of the knuckle, the center of said hole being farther from the internal wall of said knuckle clearance grooving than the cen 'ter of the periphery of the knuckle.

The methodof manufacturing a covered oint hinge member including the operations of grooving one side of a blank to provide clearance for the knuckle of the complemental hinge member, forming the knuckle by bending or curling one end of the blank toward the grooved side, and forming the pivot pin hole eccentric with respect to the periphery of the knuckle, the center of said hole being so located as to position the complemental knuckle in eccentric relation with respect to the periphery of said slotted knuckle so that the periphery of said complemental knuckle will clear the internal Wall of said grooving. i

23. The method of manufacturing a covered joint hinge member consisting in grooving one side of a fiat metal blank to provide clearance for the knuckle of a complemental hinge member, fashioning said blank to form said grooved portion into a covered joint knuckle, and crowning the covered portion of.

the knuckle while preventing disalignment of the knuckle portions.

outer member of a covered oint hinge includto provide a knuckle the imperforate grooved ing longitudinally grooving one side only of portion of which serves to conceal the knuckle a flat metal blank adjacent to one end, slotjoint. 10 ting through the blank in alignment with said In Witness of the foregoing I afiix my signa- 5 grooving from its said end inwardly to proture.

j vide separated knuckle portions, and bending or curling said slotted and grooved portions WILLIAM C. KENYON. 

